🏷️ Basic Information

Make:

Polaris

Model:

Sportsman

Model Variants:

800 EFI HO, X2 800 EFI, Touring 800, 6x6 800 EFI

Model Years Covered:

2005, 2006, 2007, 2008, 2009, 2010, 2011, 2012

Engine Code:

RFE800 (for 800cc EFI HO)

👋 Introduction

Market Position:

The Polaris Sportsman series has historically been a segment leader in the utility ATV market, known for its robust build, capable performance, and versatility for work and recreation. This manual targets owners and service professionals looking for in-depth repair and maintenance information for this popular model range.

Competitive Analysis:

Competitors in this era included models from Yamaha (Grizzly), Can-Am (Outlander), Arctic Cat (Prowler), and Honda (Rancher). The Sportsman 800 stood out with its powerful 800cc engine, independent rear suspension (IRS), and Polaris's signature On-Demand All-Wheel Drive (AWD) system.

Key Features:

This manual package consolidates information for multiple variations of the 800cc Sportsman, ensuring broad applicability. The inclusion of 'HO' (High Output) signifies enhanced engine performance. The 'X2' and 'Touring' variants indicate specific chassis and seating configurations.

📋 Manual Details

Coverage Areas:

Comprehensive coverage for all models listed, including engine, drivetrain, electrical, chassis, body, and accessories.

Page Count:

Exact page count not specified, but described as a 'COMPLETE SERVICE REPAIR MANUAL' package often encompassing hundreds of pages.

Manual Type:

Service Repair Workshop Manual

Language:

English

Format:

PDF Download

📖 Manual Coverage

Systems Covered:

Engine (disassembly, assembly, tuning, diagnostics), Fuel System (EFI, pump, injectors, filter), Ignition System, Cooling System, Exhaust System, Transmission (PVT, AWD system), Drivetrain (differentials, driveshafts, CV joints), Braking System (hydraulic, caliper, master cylinder, pads), Suspension (front and rear, shocks, springs, bushings), Steering System, Electrical System (wiring diagrams, charging, starting, lighting, instrumentation), Fuel Tank and Lines, Frame and Bodywork, Wheels and Tires, Accessories (winch, plow mounting points, storage).

Procedures Included:

Routine maintenance (oil changes, filter replacements, lubrication), tune-ups, carburetor/throttle body cleaning and adjustment, fuel injector diagnostics, coolant flush and refill, brake bleeding, suspension adjustments and component replacement, steering linkage repair, driveshaft and CV joint inspection and replacement, differential service, electrical troubleshooting, starter motor and alternator testing, lighting system repair, battery maintenance, frame inspection, body panel removal and installation, troubleshooting common issues, component testing, diagnostic procedures.

Technical Depth:

Detailed diagnostic procedures, step-by-step repair instructions, torque specifications, electrical schematics, exploded views, component identification, special tool requirements, and troubleshooting guides. Suitable for both DIY mechanics and professional technicians.

📊 Manual Specifications

File Format:

PDF

Print Quality:

High-resolution, designed for clarity when printed. Includes diagrams and illustrations.

Binding Type:

N/A (Digital Download)

Paper Type:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine:

Polaris ProStar 800 EFI HO V-Twin

Displacement:

775 cc (47.3 cu. in.)

Bore X Stroke:

Approx. 92.0 mm x 75.5 mm (3.62 in x 2.97 in)

Horsepower:

Typically around 50-55 HP, with HO variants offering slightly more.

Torque:

Approximately 45-50 ft-lbs (61-68 Nm) at peak.

Fuel System:

Electronic Fuel Injection (EFI) with Keihin or Delphi throttle body and injectors.

Cooling System:

Liquid-cooled with fan-assisted radiator.

Ignition System:

Electronic ignition, CDI unit.

Lubrication System:

Wet sump lubrication system.

🔧 Transmission

Standard:

Automatic PVT (Polaris Variable Transmission) with Engine Braking

Optional:

Not applicable; PVT is standard.

Features:

High/Low range, Neutral, Reverse. Features Polaris's On-Demand All-Wheel Drive (AWD) system, which automatically engages the front driveshaft when rear wheel slippage is detected. Many models also feature turf mode for the front differential.

Drive Type:

Shaft Drive

📐 Dimensions

Wheelbase:

Approx. 50.5 inches (128.3 cm)

Ground Clearance:

Approx. 11.25 inches (28.6 cm)

Length:

Approx. 83 inches (210.8 cm)

Width:

Approx. 46 inches (116.8 cm)

Height:

Approx. 47 inches (119.4 cm)

Dry Weight:

Approx. 660-720 lbs (299-327 kg) depending on configuration.

Towing Capacity:

1500 lbs (680.4 kg)

Rack Capacity Front:

100 lbs (45 kg)

Rack Capacity Rear:

200 lbs (90 kg)

🛡️ Safety Features

Ratings:

N/A (ATVs are not typically rated by NHTSA or IIHS like passenger vehicles).

Active Features:

Disc brakes (front and rear), Engine Braking, On-Demand AWD system, Parking brake.

Passive Features:

Integrated handguards (on some models), handlebar padding, footwells with heel guards, integrated lighting.

💡 Technology Features

Infotainment:

Basic instrumentation typically includes speedometer, odometer, trip meter, fuel gauge, and indicator lights. No advanced infotainment systems were standard on these utility models.

Driver Assistance:

The primary 'assistance' feature is the On-Demand AWD system and engine braking provided by the PVT.

Connectivity:

No integrated connectivity features like Bluetooth or smartphone integration.

🔧 Maintenance

Service Intervals:

Initial break-in service at 10 hours. Regular oil and filter changes every 100 hours or annually. Spark plug replacement, air filter cleaning/replacement, and valve adjustments typically every 100-200 hours. PVT belt inspection every 50 hours, replacement as needed. Differential and transmission fluid changes as per manual recommendations (often annually or every 100-200 hours).

Engine Oil:

Polaris Synthetic 2W-50 (or equivalent API SG or higher rated oil with similar viscosity, check manual for exact specs). Capacity: Approx. 2.5 quarts (2.4 liters) with filter.

Coolant:

Ethylene glycol-based antifreeze with corrosion inhibitors. Capacity: Approx. 2.5 quarts (2.4 liters). Use a 50/50 mix with distilled water.

Brake Fluid:

DOT 4 Hydraulic Brake Fluid.

Differential Fluid Front:

Polaris Demand Drive Fluid (or equivalent synthetic gear oil, check manual for specific type).

Differential Fluid Rear:

Polaris Synthetic Gear Oil (or equivalent SAE 75W-90 GL-5).

Transmission Fluid:

Polaris Synthetic 2W-50 (same as engine oil in many cases, verify with manual).

Known Issues:

Common issues can include PVT belt wear/failure, starter solenoid issues, radiator fan failures, voltage regulator problems, and occasional EFI system glitches. Water intrusion into electrical connectors or engine components due to improper sealing can also be problematic. The manual provides troubleshooting for these.

Oil Filter Part Number:

Polaris 3083553 (or equivalent HiFloFiltro HF198, K&N KN-198)

Air Filter Part Number:

Polaris 3089999 (or equivalent, may vary slightly by model variant)

📚 Vehicle History

Brand Heritage:

Polaris Industries Inc. has a long history dating back to 1954, initially focused on snowmobiles. They entered the ATV market in the late 1980s and quickly became a dominant force with innovations like the original Polaris Sportsman.

Model Evolution:

The Sportsman 800 was a significant evolution, building upon earlier 700cc models. The introduction of EFI provided better throttle response, fuel efficiency, and altitude compensation. The 800cc V-twin engine was a workhorse, known for its torque and reliability. The 'HO' designation typically referred to specific engine tuning or component upgrades for increased power output.

Production Locations:

Primarily manufactured at Polaris's facilities in the United States.

🏆 Awards & Recognition

Recognitions:

The Polaris Sportsman line has consistently received positive reviews and recognition from ATV publications and enthusiasts for its performance, durability, and utility features throughout its production run.